Flat-sized flexible envelope with insert

ABSTRACT

The flat oversize mail piece includes an envelope of expandable nature, a flexible insert within the pocket of the envelope and an item that may be rigid or non-rigid. The insert is provided with a cutout that is asymmetrical to one side of the insert an envelope to matingly receive the item being shipped.

This invention relates to a flat-sized flexible envelope with an insert.More particularly, this invention relates to an expandable envelopehaving an insert for receiving an item to be mailed that conforms toUSPS requirements for flexibility of flat-size pieces.

As is known, various types of envelopes have been constructed for use inmailing items, such as digital video disks (DVDs) and compact disks(CDs). In some cases, the envelopes have been provided with padding,such as described in U.S. Pat. No. 5,662,420, wherein a macerated paperlayer is sandwiched between two layers of paper.

In still other cases, as described in U.S. Pat. Nos. 5,544,473 and7,108,650, it has been known to provide envelopes in which a packingmaterial is inserted to receive an item for shipping.

Still other constructions have been known for use in shipping medicaltests specimens wherein a receptacle is provided to receive a testspecimen and the receptacle placed in an envelope, such as described inU.S. Pat. No. 5,620,097.

Recently promulgated United States Postal Service (USPS) regulations(see 39 CFR Part 111) provide standards for domestic mailing servicesthat set forth minimum flexibility criteria for flat-sized pieces.

Accordingly, it is an object of the invention to provide an envelopeconstruction that satisfies the criteria for flat-sized pieces of theUSPS.

It is another object of the invention to provide an expandable envelopeconstruction with a flexible insert for shipping items of rigid ornon-rigid nature.

It is another object of the invention to provide an expandable envelopefor mailing a DVD that qualifies for flat-sized piece postage.

Briefly, the invention provides a flat envelope having a pocket and aflexible insert within the pocket of the envelope that is of a heightand width to substantially fill the pocket. In addition, the insert isprovided with a cut-out of predetermined shape for receiving an item tobe shipped in the envelope so that the item is prevented from shiftingwithin the envelope.

In accordance with the invention, the insert may be fixed within theenvelope by a glue or adhesive or the insert may be slidably mountedwithin the envelope in an unsecured condition.

The insert may be made of any suitable material, such a self-supportingplastic foam, corrugated paper board or the like.

The item to be received within the envelope may be of rigid nature ornon-rigid nature.

In one embodiment, wherein the envelope has a dimension of at least 10inches on one side, the cut-out in the insert may be locatedsymmetrically within the insert and still meet the criteria of the USPSfor flat-sized pieces with a rigid insert.

In another embodiment, the cut-out in the insert is made asymmetricaland to one side of the insert. For example, the insert is made ofL-shape.

The envelope may be any conventional flat envelope or may be anexpandable envelope as described in U.S. Pat. No. 6,227,444. Further,the envelope may be pre-lined with padding to protect fragile contents.

These and other objects and advantages of the invention will become moreapparent from the following detailed description taken in conjunctionwith the accompanying drawings wherein:

FIG. 1 illustrates a perspective view of an envelope construction inaccordance with the invention;

FIG. 2 illustrates a view taken on line 2-2 of FIG. 1; and

FIG. 3 illustrates a view of a blank for making the envelope of FIG. 1with an insert secured in place in accordance with the invention.

Referring to FIGS. 1 and 3, the envelope 10 is an expandable envelopeconstructed in a manner as described in U.S. Pat. No. 6,227,444 from aflat blank 11.

Referring to FIG. 3, the blank 11 includes a front panel 12 ofrectangular shape and a back panel 13 that is secured to the front panel12 along a horizontal fold line 14. In addition, the front panel 12 isprovided with a rectangular array of score lines 15, each spacedinwardly from the respective edge of the panel 12 to define a rectanglewithin the panel 12 and diagonally disposed score lines 16 that connectthe corners of the rectangle of score lines 15 with the corners of thepanel 12.

The back panel 13 has a score line 17 spaced parallel to the fold line14 to separate a trapezoidal section 18 located between the fold line 14and score line 17 from a rectangular section 19.

The blank 11 also includes a pair of side flaps 20 each of which isseparated from the front panel 12 by a fold line 21 and each of whichincludes a score line 22 at an intermediate point parallel to the frontpanel 12.

Each side flap 20 has a rounded end 23 at each end as well as a scoreline 24 that extends from the score line 22 on a side flap 20 to thecorner of the front panel 12.

Each flap 20 is to be folded over the fold line 21 into folded overrelation to the front panel 12. The back panel 13 is sized to besecured, as by an adhesive, to the folded over side flaps 20 to extendto and between the score lines 21 of the flaps 20.

The blank 11 also has a closure flap 25 that is secured to the frontpanel 12 along a horizontal fold line (as viewed) 26 and that includes ascore line 27 spaced from the fold line 26 to separate a trapezoidalsection 28 from a rectangular section 29.

Referring to FIGS. 1 and 3, the closure flap 25 includes a strip ofadhesive or glue 30, such as a gummed or latex adhesive, for closingonto the back panel 13 as well as a removable strip 31 that covers overthe adhesive 30 until the adhesive 30 is ready for use.

Referring to FIG. 3, each side flap 20 is provided with a line ofadhesive (not shown) on the underside (as viewed) of the section betweenthe score line 22 and the free edge of the flap 20 for securement to theunderside of the back panel 13.

In order to form the envelope 10 of FIG. 1, the blank 11 of FIG. 3 ismanipulated manually and/or mechanically in an automated manner in thefollowing manner.

First, the side flaps 20 are folded along the fold lines 21 over thefront panel 12. Next, the back panel 13 is folded about the fold line 14onto the exposed adhesive on the side flaps 20. In this respect, theback panel 13 is of a width to extend to and between the score lines 22of the side flaps 20, as indicated in FIG. 1. At this time, thetrapezoidal section 18 of the back panel 13 covers over the lower ends23 of the side flaps 20 in an overlapping manner and completely sealsthe two lower corners of the envelope 10. Also, the two upper corners ofthe back panel 13 lie over the rounded ends 23 of the side flaps 20 toleave the uppermost rounded ends 23 of the side flaps 20 exposed.

Once the back panel 13 is secured in place as shown in FIG. 1, a pocketis formed within the envelope 10.

Referring to FIG. 3, a flexible insert 32 is secured to the front panel12, for example by a suitable adhesive. As illustrated, the insert 32 isof L-shape and defines a cut-out located asymmetrically to one side ofthe insert 32 for receiving an item 33 (see FIG. 1) to be shipped in thecompleted envelope 10.

The insert 32 is made of any suitable material, such as a selfsupporting plastic foam, cardboard or the like. Preferably, alightweight plastic foam is used.

As indicated in FIG. 3, the insert 32 extends width-wise to and betweenthe vertical score lines 15 of the front panel 12 and extendsheight-wise to and between the horizontal score lines 15 of the frontpanel 12 in order to substantially fill the pocket of the envelope 10.

Referring to FIG. 2, the insert 32 has a thickness of from 1/16 inchesto 1¼ inches and preferably a thickness of ½ inch. The thickness of theinsert 32 may be up to ¾ of an inch.

Alternatively, the insert 32 need not be secured to either the frontpanel 13 or the back panel 13. In this case, the insert 32 may be slidinto the pocket of the envelope 10 after the envelope has beenfabricated. For example, the insert 33 may be inserted into the envelopeby a user when the item 33 is being inserted.

Further, the insert 32 may be dropped onto a die cut flat sheet and thenthe sheet closed around the insert 32 and rigid inserted item 33creating an envelope.

When the insert 32 is in place, the pocket of the envelope 10 isexpanded into the condition as indicated in FIG. 2. As viewed, theinsert 32 extends to and between the vertical score lines 15 of thefront panel 12 and to and between the score lines 22 of the side flaps20. Also, the edges of the front panel 12 beyond the vertical scorelines 15 bend downwardly, as viewed, and the sections of each side flap20 between the respective fold line 21 and score line 22 bend upwardly,as viewed, to define V-shaped side edges to the envelope 10. A similarV-shaped bottom edge to the envelope 10 is also formed. As a result, theinsert 32 being of a thickness equal to the largest width of theV-shaped side and bottom edges of the envelope 10 is restrained fromshifting sideways or vertically, and particularly, no more than 1 inchin an envelope 10 of a 9 inch×12 inch size with score lines 15 on thefront panel 12 being spaced ¼ inch from the edges of the front panel 12and the insert 32 being ½ inch in thickness.

Insertion of the insert 32 may be accomplished manually or automaticallythrough suitable mechanical equipment.

Referring to FIG. 1, the item 33 may be rigid, such as a DVD holder or aCD holder, or the item may be non-rigid, i.e. flexible. In either case,the item 33 is matingly disposed within the cut-out of the insert 32. Inthis respect, the item 33 has a shape corresponding to the shape of thecut-out and a thickness corresponding to the thickness of the insert 32.

The item 33 may be inserted into the cut-out of the insert 32 within thepocket of the envelope 10 manually or automatically. Further, the item33 and insert 32 may be inserted in the same operation by any suitablemeans. After the item 33 has been inserted into the cut-out of theinsert 32, the removable cover strip 31 is removed and the closure flap25 folded via the fold line 26 over the back panel 13 in order to closethe pocket and seal the item 33 therein.

Upon closing over of the closure flap 25, the trapezoidal section 28 ofthe closure flap 25 over lies the rounded ends 23 of the side flaps 20to seal the two upper corners of the envelope 10. At the same time, theremainder of the closure flap 25 is of a width equal to the width of theback panel 13 to form a neat closure herewith.

The envelope 10 may be of any suitable size. For example, for shipping aDVD holder, the envelope, when closed, has a width of 12-½″ and a heightof 10″. In addition, the insert 32 is of ½″ thickness and the DVD holder33 has a corresponding ½″ thickness, a width of 7.5″ and a height of5.25″.

The envelope 10 with the insert 33 therein conforms to the recentlypromulgated United States Postal Service (USPS) requirements for minimumflexibility criteria for fiat-size pieces. The test for flats is asfollows:

-   -   1. Place the piece with the length parallel to the edge of the        flat surface and extend piece half way off the surface;    -   2. Press down on the piece at a point 1 inch from the outer        edge, in the center of the piece's length, exerting steady        pressure;    -   3. The piece is not flexible if it cannot bend at least 1 inch        vertically without being damaged;    -   4. The piece is flexible if it can bend at least 1 inch        vertically without being damaged and it does not contain a rigid        insert.

If the piece is a flat 10 inches or longer and contains a rigid insert,the following tests are to be conducted:

-   -   1. Place the piece with the length perpendicular to the edge of        a flat surface and extend the piece 5 inches off the surface;    -   2. Press down on the piece at a point 1 inch from the outer        edge, in the center of the piece's length, exerting steady        pressure;    -   3. Turn the piece around and repeat steps 1 and 2. The piece is        flexible if both ends can bend at least 2 inches vertically        without being damaged.

The following test is for flats less than 10″ and that contains a rigidinsert:

-   -   1. Place the piece with the length perpendicular to the edge of        a flat surface and extend the piece one-half of its length off        the surface;    -   2. Press down on the piece at a point one inch from the outer        edge, in the center of the piece's width, exerting steady        pressure;    -   3. Turn the piece around and repeat steps 1 and 2; the piece is        flexible if both ends can bend at least 1 inch vertically        without being damaged.

The envelope 10 as shown in FIG. 1 that is stuffed with a DVD holder 33as described above and being of a size of 12½″ wide and 10″ high passesthe minimum flexibility criteria for flat-sized pieces of the USPS forflats 10 inches or longer that contain a rigid insert.

An envelope having dimensions of 9⅞ inches wide and 8 inches high with aCD holder 5⅞ inches wide×4⅞ inches high asymmetrically to one side ofthe cut-out in the insert 32 also passes the USPS minimum flexibilitycriteria for flats less than 10 inches long and that contain a rigidinsert.

The combination of envelope, flexible insert and packaged item may havedifferent relative sizes in order to pass the flexibility tests of theUSPS. For example, the envelope may have a maximum size of 12″ high and15″ wide.

Further, the insert 32 may have one or more cutouts for receiving rigiditems other than rectangular items, such as DVD holders and CD holders.For example, for a large size envelope, the insert may have a cut-outthat is symmetrically placed. Further, such a cut-out may be of anysuitable shape such as rectangular, circular, or otherwise, to receive acircular item or otherwise Further, the insert 32 may be provided with aslit in order to receive a slender item, such as a pencil.

As noted above, the envelope may be pre-lined with padding. In such anembodiment, the insert 32 may be fixed or not in place.

The invention thus provides a combination of envelope and insert that isable to receive and retain rigid or non-rigid items, as defined by theUSPS, in place for shipment through the USPS as a flat-sized piece.

The envelope and insert satisfies the USPS requirement that a flat-sizedmail piece be uniformly thick so that any bumps, protrusions or otherirregularities do not cause more than ¼″ variance in thickness.

Excluding the outside edges of a mail piece, i.e., one inch from theedge, when determining variance in thickness, the insert secures theitem within the cutout of the insert 32 so as to prevent shifting ofmore than 2″ within the envelope.

1. In combination, a flat envelope including a front panel, a backpanel, a pair of side flaps disposed in folded relation relative to saidfront panel and said back panel to define a pocket therewith and aclosure flap for closing over said pocket; and a flexible insert withinsaid pocket of said envelope, said insert being of a height and width tosubstantially fill said pocket, said insert having a cut-out ofpredetermined shape for receiving an item to be shipped in saidenvelope.
 2. The combination as set forth in claim 1 wherein said insertis secured to at least one of said panels.
 3. The combination as setforth in claim 1 wherein said insert is made of self-supporting plasticfoam.
 4. The combination as set forth in claim 1 wherein said insert isof L-shape and said cut-out is disposed asymmetrically to one side ofsaid insert.
 5. The combination as set forth in claim 1 wherein saidenvelope has a dimension of at least ten inches on one side thereof. 6.In combination an expandable envelope construction comprising a pair ofpanels folded over each other along a horizontal fold line; at least afirst panel of said panels having a horizontally disposed score linespaced from a bottom edge thereof, a horizontally disposed score linespaced from a top edge thereof, a vertically disposed score line spacedfrom one side edge thereof, a vertically disposed score line spaced fromanother side edge thereof and a plurality of angularly disposed scorelines, each said angularly disposed score line extending from anintersection of a respective horizontally disposed score line and avertically disposed score line to a respective corner of said firstpanel; a pair of side flaps at opposite sides of one of said pair ofpanels, each said flap being folded over said one panel along a verticalfold line therebetween and being secured to the other of said pair ofpanels to form a pocket; and a closure flap extending from said one ofsaid pair of panels along a horizontal fold line therebetween forfolding over the other of said pair of panels to close said pocket, saidclosure flap having a horizontally disposed score line spaced from saidfold line between said closure flap and said one of said pair of panelswhereby upon insertion of materials into said pocket, said panels areexpandable from each other to enlarge the thickness of said pocket whilesaid pocket is maintained in a sealed condition; and a flexible insertwithin said pocket of said envelope, said insert extending between saidscore lines of said first panel, said insert having a cut-out ofpredetermined shape for matingly receiving an item to be shipped in saidenvelope, said cut-out being disposed asymmetrically of said insert. 7.The combination as set forth in claim 6 wherein each said flap has avertical score line spaced from said first panel and wherein the otherof said panels is secured to each said side flap between said scorelines thereof to seal said pocket at at least each of two corners ofsaid envelope construction.
 8. The combination as set forth in claim 6wherein said insert is secured to at least one of said flaps.
 9. Thecombination as set forth in claim 6 wherein said insert has a thicknessof from 1/16 inches to 1¼ inches.
 10. In combination, an envelopeincluding a front panel, a back panel, a pair of side flaps disposed infolded relation relative to said front panel and said back panel todefine a pocket therewith and a closure flap closing over said pocket; aflexible insert within said pocket of said envelope, said insert havinga predetermined thickness and being of an overall height and width tosubstantially fill said pocket, said insert having a cut-out ofpredetermined shape disposed asymmetrically of said insert; and an itemmatingly disposed in said envelope within said cut-out of said insert,said item having a shape corresponding to said predetermined shape ofsaid cut-out and a thickness corresponding to said predeterminedthickness of said insert.
 11. The combination as set forth in claim 10wherein said item is flexible.
 12. The combination as set forth in claim11 wherein, with an uppermost half of said envelope supported on ahorizontal plane, a lowermost half of said envelope is bendable relativeto said horizontal plane about a longitudinal axis located at mid-heightthereof to deflect a lowermost edge thereof for a vertical distance ofat least one inch from said horizontal plane.
 13. The combination as setforth in claim 10 wherein said item is rigid.
 14. The combination as setforth in claim 13 wherein, with an uppermost half of said envelopesupported on a horizontal plane, a lowermost half of said envelope isbendable relative to said horizontal plane about a longitudinal axislocated at mid-height thereof to deflect a lowermost edge thereof for avertical distance of at least one inch from said horizontal plane. 15.The combination as set forth in claim 14 wherein, with one side of saidenvelope supported on said horizontal plane and five inches of theopposite side of said envelope projecting in an unsupported manner, saidopposite side of said envelope is bendable relative to said horizontalplane to deflect an edge thereof for a vertical distance of at least twoinches from said horizontal plane.
 16. The combination as set forth inclaim 15 wherein, with said opposite side of said envelope supported onsaid horizontal plane and five inches of said one side of said envelopeprojecting in an unsupported manner, said one side of said envelope isbendable relative to said horizontal plane to deflect an edge thereoffor a vertical distance of at least two inches from said horizontalplane.
 17. The combination as set forth in claim 10 wherein said item isa CD holder.
 18. The combination as set forth in claim 10 wherein saiditem is a DVD.
 19. The combination as set forth in claim 10 wherein saidinsert is made of self-supporting plastic foam.
 20. The combination asset forth in claim 10 wherein said insert is of L-shape and said cut-outis disposed to one side of said insert to prevent shifting of said itemin said envelope.
 21. The combination as set forth in claim 10 whereinsaid insert and said item are of equal thickness.
 22. In combination, aflat envelope having a dimension of at least ten inches on one sidethereof and including a front panel, a back panel, a pair of side flapsdisposed in folded relation relative to said front panel and said backpanel to define a pocket therewith and a closure flap closing over saidpocket; a flexible insert within said pocket of said envelope, saidinsert having a predetermined thickness and being of an overall heightand width to substantially fill said pocket, said insert having acut-out of predetermined shape; and an item matingly disposed withinsaid cut-out of said insert, said item having a shape corresponding tosaid predetermined shape of said cut-out and a thickness correspondingto said predetermined thickness of said insert.
 23. The combination asset forth in claim 22 wherein said cut-out is disposed asymmetrically ofand to one side of said envelope and said item is rigid.
 24. Thecombination as set forth in claim 22 wherein said insert is of L-shape.